Method of forming cone clutch members



Aug. 23, 1938. c. M. EAsoN METHOD OF FQRMING GONE' CLUTCH MEMBERS 2 sheet-sneet 1 Original Filed May 27. 1955 IIT Aug. 23, 1938. c. M. EAsoN METHOD OF FORMING GONE CLUTCH MEMBERS Original Filed May 27, 1935 2 Sheets-Sheet 2 Patented Aug. 23, 1938 UNITED STATES PATENT OFFICE METHODy OF FORMING GONE CLUTCH MEMBERS Clarence M. Eason, Waukesha, Wis, assigner to Industrial Clutch Company, a corporation of Wisconsin 8 Claims.

This invention relates to cone friction clutches. The present application is a division of my prior Patent No. 2,090,411, issued August 17, 1937,

and my prior Patent No. 2,059,935, issued Novem- 5 ber 3, 1936.

One of the main objects of the invention is to provide a new method of forming a cone clutch member which comprises forming a flat blank to the desired configuration, forming in said blank circumferentially spaced notches which open from the outer periphery of the blank and extend inwardly from the outer periphery of the blank, folding and forming the segmental margin portions of the blank between said notches l5 into the form of a cone rim, and securing friction facing material upon said margin portions.

It is also an object of the invention to provide a new method of forming a cone clutch member which comprises forming a flat blank to the desired configuration, forming in said blank circumferentially spaced notches which open from the outer periphery of the blank and extend inwardly from the outer periphery of the blank, securing separate friction facings, preferably of high unit pressure capacity, upon the portions of the blank between said notches and in proximity to the outer margin of the blank while the blank is flat, and thereafter folding and forming the segmental margin portions of 30 the blank between said notches into the form of a cone r1m.

It is a further object of the invention to provide a new method of forming a cone clutch member which comprises forming a flat blank to the desired configuration, forming in said blank circumferentally spaced notches which open from the outer periphery of the blank and extend inwardly from the outer periphery of the blank, folding and forming the segmental margin portions of the blank between. said notches into the form of a cone rim, securing friction facing material upon said margin portIons, and thereafter dividing the member into a plurality of arcuate segments for separate attachment to and removal from a cone rim carrying member.

Further objects and advantages of the invention will be apparent from the following detailed description, taken in connection with the accompanying drawings in which:

Figure 1 is a rear elevational view of a cone rim part embodying the present invention, showing, in dotted lines, the manner of forming the same from flat stock without drawing operations;

Figure 2 is a vertical section taken on the line 2 2 of Figure 1;

Figure 3 is a fragmentary detail section of the cone rim part, showing how the same springs in or collapses in engagement of the clutch, and springs out or expands to an angle slightly greater than the angle of the female clutch surface when the clutch is disengaged;

Figure 4 is a rear elevational View of one of the segments into which the cone rim part is divided; v

Figure 5 is a fragmentary view showing the flat blank which is formed into the cone clutch member according to another embodiment of the invention;

Figure 6 is a fragmentary front elevational view of the member shown in Figure 5 after folding and forming the same to the desired form; and

Figure 7 is a fragmentary detail section through the cone clutch member formed according to the present invention from the blank shown in Figure 5.

Referring first to Figures l, 2, 3, and 4, the cone clutch member i selected for illustration is in the form of a cone clutch driven member movable into and out of engagement with the inner or female clutch surface Il of conical form on the flywheel l2, shown in dotted lines in Figure 2, or other driving member.

The cone clutch member l0 is divided into an outer cone rim part lila and an inner cone rim Supporting part 10b. The outer margin of the inner part 10b is offset forwardly as shown in dotted lines in Figure 2, andl the forward end of the cone rim part 19d has an inturned radial flange i3 secured to the outer margin of the inner part `10b by means of bolts I4. segmental reenforcing pieces l are preferably spot-welded at l5 (Figure 4) to the flange I3 of the cone rim part to lie between this flange and the heads of the bolts lll, and washers may be employed as and where desired.

The cone rim part a is preferably made from sheet steel of the desired gauge, or other suitable flat stock. The flat sheet is stamped or otherwise in Figure 3.

cut to the annular form shown in Figures l and 2, the outer periphery being shaped to the configuration indicated at Il, and the central portion of the sheet being removed along the inner periphery I8 of the annular member thus formed. The flat annular member is notched or divided at circumferentially spaced positions along its outer periphery as shown at I9. These notches or divisions I9 are of generally V-shaped form, with their wide ends at the outer periphery Il of the flat annular member and their inner ends spaced outwardly from the inner periphery I8 a radial distance approximately equal to the radial dimension of the flange I3. The inner periphery I8 is scalloped at three positions equi-spaced circumferentially, as shown at 20, to give clearance around the tubular bosses (not shown) formed on the inner cone clutch part Ib as illustrated in my prior Patent No. 2,090,411, issued August 17, 1937.

The blank out or punched centrally from the flat annular member may be used as the clutch abutment plate as more fully disclosed in the foregoing patent, in which case it may be provided with a central opening and formed as desired.

The annular blank with its outer margin slotted or notched, and which is to constitute the cone rim part, is then placed between a pair of conical die members (not shown) and pressed to form the conical rim part with the flange I3 as shown in Figure 4. The die means, instead of drawing a conical rim from flat stock, which is a difcult manufacturing operation requiring large and expensive presses, merely folds or forms the freed portions 22 between the notches I9 in from the plane of the flange part I3 to the desired conical form as shown. The performance of this bending and forming operation between the pair of conical die members is a single shaping operation, as distinguished from the multiple operations necessary in a drawing or swaging method of treatment. The edges 23 of the segment-like portions 22 preferably abut when the rim is collapsed or contracted as shown in dotted lines lThe cone rim thus collapsed or contracted is in the form of a continuous arch structure with each segment-like portion acting as a keystone or arch in said structure. As a result, this arched structure of the cone rim has just as much strength as a solid cone rim.

By avoiding the diflicult drawing operations for drawing a cone rim from flat stock and employing merely a folding and forming operation to bring the segment-like portions 22 to the desired conical form, the cost and difliculty of forming the cone rim are greatly reduced. rlIhe drawing operations heretofore employed, in addition to being difficult, required large and costly presses, whereas the folding and forming operation which I employ can be done on a small inexpensive press. The use of the central portion of the flat stock, which is stamped or otherwise removed from within the inner periphery I8 of the annular cone rim forming member, as the abutment plate further reduces the cost.

In addition, due to the inherent springiness of the stock; which is preferably employed, the conical segments 22 have a tendency to spring open slightly. This gives the conical rim of the cone member I a slightly greater angle than the cooperating female cone surface I of the flywheel or driving clutch part I2 as shown in full lines in Figure 3. As a result, when the clutch is engaged, the cone rim bears, rst, on its outer enlarged portion and, with comparatively little force, is collapsed to pro-per angularity as shown in dotted lines in Figure 3 for full engagement with the clutch surface II. This gives a softer acting clutch which engages more smoothly and in which the tendency of the clutch to grab, stutter, or chatter during engagement is eliminated.

This springiness of the cone rim part in the operation of the clutch is an important aspect of the present invention. The advantages above set forth are obtained without placing a spring under the clutch facing or lining to give an initial grab and mal/re the clutch smoother acting as commonly resorted to heretofore in the art. When the cone rim Ilia is in full engagement with the clutch surface II, the edges 23 of the segment-like portions 22 are, as already pointed out, preferably in abutting engagement and present a solid cone rim of great strength.

Upon bringing the cone rim part Ill into the desired conical form in the manufacture of this part, it is completed, turned, machined, or otherwise finished, and the lining or facing 25 is secured thereto as by means of rivets 26, preferably while the part It] is in one piece. The lining or facing 25 may be the usual or any suitable or preferred friction facing or lining material. The completion and finishing of the cone part EI) with its friction facing 25, while this part Ill is in one piece, enables bringing this part to true and accurate form.

After the part I@ has been completed and nished and the friction facing 25 has been applied thereto, this part, with its facing 25, is then divided at 28, 29 and 3Q into three or any other desired number of equal length segments. The divisions 28, 29 and 39 are preferably equispaced circumferentially so that the cone segments will be interchangeable, but this may vary within the scope of the present invention. The cone segments are secured to the inner hub part Hlb by the bolts lf2, and the sectionalized cone clutch driven member I, comprising the cone rim section constituting the outer cone part Illa and the inner part part Ib, is ready for use.

The three segments constituting the cone rim part Ia` are preferably of convenient size to be easily removed and replaced through the handhole of the clutch housing (not shown). bolting the cone Segments forming the cone rim Illa from the inner part Ib, these segments may be separately removed as for example, through the usual hand-hole, refaced with friction facing material 25, returned through the hand-hole, and reapplied toI the inner part Ib without taking the driving shaft or other parts away from the driving clutch part as heretofore necessary where the cone clutch part was made up in one piece. And removal and refacing of the cone segments are permitted without separating the clutch housing from the flywheel housing or otherwise dismantling the clutch.

The cone clutch member 35 shown in Figures 5, 6, and 7, with its cone rim 35, is likewise preferably made of sheet steel of the desired gauge, or other hat stock similar to the stock employed in connection with the preceding embodiment of the invention. This flat sheet is stamped or otherwise cut to the form shown in Figure 5, and its outer periphery is notched at circumferentially spaced locations at 3l. The notches 3l are of generally V-shaped form, with their wide ends at the outer periphery 33 of the fiat member and their inner ends spaced outwardly By un- CTI from the inner periphery of the rim forming part of the member. Circumferentially spaced sectorlike portions are stamped or otherwise cut out to form the openings 39 with the radial arms or spokes All disposed between the respective openings. The outer ends of the arms lill are integral with the rim forming part of the plate, and the inner ends of these arms are separated and shaped as shown at 4L The blank, with its outer margins slotted at 31 and which is to constitute the sliding clutch member, is placed between a pair of conical die members (not shown) and. pressed to form the conical rim part 36 with the flange A12 and the connecting arms @il as shown in Figures 6 and 7. The folding or forming of the freed portions 45 between the notches 31 in from the plane of the ilange l2 to the desired conical form, as distinguished from drawing a conical rim from flat stock, has the advantages set forth in connection with the preceding embodiment of the invention. The edges Il@ of the segment-like portions 45 preferably abut when the rim is collapsed or contracted, whereby the cone rimis in the form of a continuous arch structure with each segment-like portion l5 acting as a keystone or arch in said structure. As a result, the cone rim has just as much strength as a solid cone rim when in full engagement with the cooperating clutch member.

As in the preceding embodiment of the invention, the conically arranged segments 45 have a tendency to spring open slightly due to the inherent springiness of the sto-ck which is preferably employed. As in the preceding embodiment, this gives the conical rim 36 a slightly greater angle than the cooperating female cone surface of the cooperating clutch member. As a result, when the clutch is engaged, the cone rim bears first on its outer enlarged portion and, with comparatively little force, is collapsed to proper angularity for full engagement with the cooperating clutch surface. When in full engagement, the edges of the segment-like portions preferably abut and provide a cone rim of great strength.

The outer conical surfaces of the cone rim segments 45 are faced with a friction material preferably of high unit pressure capacity. This friction material may be in the form of thin light-weight metallic friction pads 5@ of high unit pressure capacity brazed to the conical rim forming segments liti. Instead of being in the form of separate circumferentially spaced pads 5l), this metallic friction facing may be in the form of arcuate facing strips, each of a length substantially equal to the lengths of the respective segments 45.

Friction facings formed of this material may be very thin and light in weight and, at the same time, are capable of taking five times as much pressure per unit of area as any of the friction materials now comonly employed in cone clutches. It is to be understood that any friction material of high unit pressure capacity may be employed within the scope of this aspect of the invention, and certain features of the present in vention may be employed regardless of the character of the friction facing material.

In the case of metallic friction facings of high unit pressure capacity, these facings are preferably braZed or secured tothe cone rim forming part in equivalent manner while the blank is flat and, preferably, before folding and forming the segment-like portions 45 and the arms Ml to the desired form. Where the friction material is secured to the cone rim forming part while the blank is flat, the segment-like portions 45 are preferably relatively short circumferentially, i. e., the notches 3l are disposed about an inch apart. It is to be understood, however, that the present invention is not limited to the particular lengths of these segment-like portions unless such lengths are specically included in the appended claims.

The folding and forming of the cone rim tothe desired shape as distinguished from drawing it to shape, has special correlation with respect to the friction facing or facings of high unit pressure capacity, in that these facings may be applied to the flat blank and the blank then folded and formed to shape without cracking or loosening the facings. if the outer margin of the blank were continuous and drawn to shape, the friction facings would be subjected to the drawing operation, and because of brittleness, would tend to crack or loosen from the plate.

Upon bringing the cone rim part into the desired conical form and sloping the arms il@ rearwardly and inwardly with their inner ends turned radially, the cone rim 35 is applied to the hub 6d. The hub eli has an annular groove @l and an annular shoulder d2. The inner ends of the arms t@ are placed against the shoulder 62, with their inner edges engaged in the groove @i as shown in Figure '7. The inner ends ofthe arms have small openings 53 adjacent recesses M in the hub, and the walls of the arms itl adjacent the openings t3 are punched into recesses '45d to hold the inner ends of the arms 40 against radial displacement from the hub and to connect the cone rim 315 and hub @il against relative rotation. The disc lit is the disc of the flexible driving connection between the cone rim part and the driving hub, as more fully disclosed in my prior patent number 2,059,935 issued November 3, 1936. This disc is riveted at d' to the flange portion 152 of the sliding cone member, the fiange t2 being provided with apertured scallops 59 for this purpose, as shown in Figure 6.

I do not intend to be limited to the precise details shown or described.

I claim:

l. The method of forming a cone clutch member which comprises forming a flat blank to the desired configuration, forming in said blank circumferentially7 spaced notches which open from the outer periphery of the blank and extend inwardly to positions spaced inwardly from the outer periphery of the blank, securing separate friction facings preferably of high unit pressure capacity upon the portions of the blank between said notches and in proximity to the outer margin of the blank while the blank is flat, and thereafter folding and forming the segmental margin portions of the blank between said notches into the form of a cone rim.

2. The method of constructing a male cone clutch member consisting of a plurality of substantially identical arcuate sections, which co1nprises rst producing a substantially fiat circular blank having a relatively large circular area cut out of the center of the blank, welding segmental reenforcing members to the inner peripheral portion of the blank, cutting out a plurality of V--shaped notches in the outer peripheral portion of the flat blank to denne a series of circumferential segments between said notches, then pressing said blank between inner and outer conical dies to effect, in a single op eration, the bending of said circumferential segments substantially to the pitch angle of the desired cone and also to effect the forming of said circumferential segments to the circular cross section of said cone, whereby to form a conical rim flaring outwardly from the radially extending portion of the blank, said notches being proportioned whereby suiiicient surplus metal is removed so that substantially no drawing of the remaining metal in said circumferential segments is necessary in the operation of bending and forming said conical rim, but in which conical rim the adjacent edges of the circumferential segments are in such close proximity that said edges will be caused to abut with each other when the clutch member is pressed into its coacting clutch element, then securing friction facing material to the outer surfaces of said segments, and finally dividing the member into a plurality of arcuate sections for separate attachment to and removal from a cone clutch carrying member.

3. rI'he method of constructing a male cone clutch member consisting of a plurality of substantially identical arcuate sections, which comprises first producing a substantially flat circular blank having a relatively large circular area cut out of the center of the blank, cutting out a plurality of V-shaped notches in the outer peripheral portion of the fiat blank to define a series of circumferential segments between said notches, then pressing said blank between inner and outer conical dies to effect, in a single operation, the bending of said circumferential segments substantially to the pitch angle of the desired cone and also to effect the forming of said circumferential segments to the circular cross section of said cone, whereby to form a conical rim flaring outwardly from the radially extending portion of the blank, said notches being proportioned whereby suicient surplus metal is removed so that substantially no drawing of the remaining metal in said circumferential segments is necessary in the operation of bending and forming said conical rim, but in which conical rim the adjacent edges of the circumferential segments are in such close proximity that said edges will be caused to abut with each other when the clutch member is pressed into its coacting clutch element, then securing friction facing material to the outer surfaces of said segments, and finally dividing the member into a plurality of arcuate sections for separate attachment to and removal from a cone clutch carrying member.

fi. The method of constructing a male cone clutch member consisting of a plurality of substantially identical arcuate sections, which comprises rlrst producing a substantially nat circular blank having an opening in the center thereof, cutting out a plurality of V-shaped notches in the outer peripheral portion of the flat blank to define a series of circumferential segments between said notches, then pressing said blank between inner and outer conical dies to effect, in a single operation, the bending of said circumferential segments substantially to the pitch angle of the desired cone and also to effect the forming of said circumferential segments to the circular cross section of said cone, whereby to form a cone rim flaring outwardly from the radially extending portion of the blank and in which the adjacent edges of the circumferential segments are in such close proximity that said edges will be caused to abut with each other when the clutch member is pressed into its coacting clutch element, and dividing the member into a plurality of arcuate sections for separate attachment to and removal from a cone clutch carrying member.

5. The method of constructing a male cone clutch member consisting of a plurality of substantially identical arcuate sections which comprises rst producing a substantially ilat circular blank having an opening in the center thereof, cutting out a plurality of V-shaped notches in the outer peripheral portion of the blank to define a series of circumferential segments between said notches, then pressing said blank between inner and outer conical dies to effect the bending of said circumferential segments substantially to the pitch angle of the desired cone and also to effect the forming of said circumferential segments to the circular cross section of said cone, whereby to form a cone rim in which the adjacent edges of the circumferential segments are in such close proximity that said edges will be caused to abut with each other when the clutch member is pressed into its coacting clutch element, and dividing the member into a plurality of arcuate sections for separate attachment to and removal from a cone clutch carrying member.

6. The method of constructing a male cone clutch member consisting of a plurality of substantially identical arcuate sections, which comprises iirst producing a substantially circular blank having an opening in the center thereof, cutting out a plurality of notches in the outer peripheral portion of the blank to define a series oi' circumferential segments between said notches, then pressing said blank between inner and outer conical dies to bend said circumferential segments substantially to the pitch angle of the desired cone and also to shape said circumferential segments to the circular cross section of said cone, whereby to form a cone rim flaring outwardly from the radially extending portion of the blank, securing friction facing material to the outer surfaces of said segments and dividing the member into a plurality of arcuate sections for separate attachment to and removal from a cone clutch carrying member.

7. The method of making a cone clutch member consisting of a plurality of separate arcuate sections, which comprises cutting a plurality of notches in the outer peripheral portion of a substantially flat disk to form a series of circumferential segments between the notches, then pressing said disk between a pair of conical dies to bend said segments into the form of a conical flange flaring outwardly from the substantially radially extending portion of the disk, and then dividing the flanged disk into a plurality of arcuate sections for separate attachment to and removal from a cone clutch carrying member,

8. The method of constructing a male cone clutch member, which comprises first producing a substantially fiat circular blank having an opening in the center thereof, cutting out a plurality of inwardly extending V-shaped notches in the outer peripheral portion of the blank to denne a series of circumferential segments between said notches, then pressing said blank between inner and outer conical dies to effect, in a single operation, the bending of said circumferential segments substantially to the pitch angle of the desired cone and also to effect the forming of said circumferential segments to the 75 circular cross section of said cone, whereby to form a cone rim flaring outwardly from the radiall;7 extending portion of the blank and in which the adjacent edges of the circumferential segments are in such close proximity that said edges Will be caused to abut with each other when the clutch member is pressed into its coacting clutch element, and then securing friction facing material to the outer surfaces of said segments.

CLARENCE M. EASON. 

